S539 Service Manual
Contents
1. Press the black clasper 1 09 to separate the front and rear section See Illus 10 2 4 1 To replace the front shroud see Illus 08 When to replace the shroud lt gt The shroud is broken How to replace the shroud lt gt Please proceeding following steps 1 Loosen screws 7 29 and take the foot matt 7 28 off 2 Use screw driver to loosen six screws 7 27 and then remove replace the shroud 7 21 2 4 2 To replace the front wheel assembly See Illus 09 When to replace the front wheel assembly lt gt The front wheel assembly is worn out pierced or deformed 9 How to replace the front wheel assembly lt gt Please proceeding following steps 2 4 3 2 4 4 1 Hold the screw 3 03 and loosen the nut 3 05 2 Remove replace the front wheel 3 02 To replace the controller see Illus 10 When to replace the controller lt The controller is not working properly How to replace the controller lt gt Please proceeding following steps 1 Unplug all connectors on the controller 2 Use screwdriver to loosen screws 1 39 and then remove replace the controller 1 38 To replace the frame clasper See Illus 10 When to replace the frame clasper lt gt The frame clasper is deformed or out of shape lt gt The front and rear section can not link together securely How to replace the frame clasper lt gt Please proceeding following steps Use hex tools2. 1 Pull the key 5 63 out 2 Lossen the nut on the key switch 5 53 3 Remove replace the key or key switch To replace the upper cover See Illus 11 When to replace the upper cover lt gt The upper cover is broken How to replace the upper cover lt Please proceeding following steps 1 Separate the lower and upper cover See 2 5 2 2 Remove the throttle lever and variable resistance See 2 5 3 3 Remove the horn button and buzzer See 2 5 4 4 Remove the power indicator See 2 5 5 5 Remove the knob and potentiometer See 2 5 6 6 Remove the key and key switch See 2 5 7 7 Replace the upper cover 5 51 Illus 11 14
3. To replace the lower cover assembly See Illus 03 When to replace the lower cover or related parts lt gt If the lower cover or battery is worn out or broken How to replace the lower cover or relation parts lt Please proceeding following steps Use screwdriver to loosen 8 screws 9 42 to open the cover assembly 2 Unplug the harness 9 41 loosen nut 9 38 and then remove the conducts 9 37 3 Remove replace the battery 9 40 and replace the lower cover 9 33 2 2 2 To replace the upper cover assembly See Illus 03 When to replace the upper cover or related parts lt gt The upper cover circuit breaker charger socket set or handle is worn out or broken lt gt If the circuit breaker can not reset or broken 9 How to replace the upper cover or relation parts lt gt Please proceeding following steps 1 Take the battery pack assembly out and separate the upper and lower covers See 2 2 1 2 Loosen the circuit breaker cap 9 23 by hand Remove replace the circuit breaker 9 22 3 Use screwdriver and wrench to loosen the screw 9 28 and nut 9 30 and then remove replace the charger socket set 9 27 4 Use screwdriver to loosen screws 9 32 5 Remove replace the handle 9 31 or the upper cover 9 21 Illus 03 2 3 How to replace or repair the Rear Section Assembly The rear section assembly is composed of the rear frame the transaxle assemb
4. Merits SI39 23 7 Service Manual Index Introduction ijas PI Service Guide essessesscsscsscsecsecssesecsesseessessessessessessesscsesssssessessessessess PI 2 1 How to replace or repair the Seat Assembly ssss PI 2 1 1 To replace the seat body P1 2 1 2 To replace the armrest assembly P1 2 1 3 To replace the seat base plate assembly P3 2 2 How to replace or repair the Battery Pack Assembly ps 2 2 1 To replace the lower cover assembly P3 2 2 2 To replace the upper cover assembly P3 2 3 How to replace or repair the Rear Section Assembly P4 2 3 1 To replace the rear shroud P5 2 3 2 To replace the anti tip wheel nne P5 2 3 3 To replace the driven wheel assembly sssssssssssss eee P5 2 3 4 To replace the transaxle assembly sess P5 2 3 5 To replace the Pear frame ecce dee dites den tee tt RR Ree i b va YHP PER eee Eees P7 2 4 How to replace or repair the Front Section Assembly P8 2 4 1 To replace the front shroud ssss sse eene nennen nnns P8 2 4 2 To replace the front wheel assembly ssesssssssseeeeenenen P8 2 4 3 To replace the controller sus P8 2 4 4 To replace the frame clasper sssssssssssssseseeeeeen enemies P9 2 4 5 To replace the front fr
5. ame P9 2 5 How to replace or repair the Tiller Assembly PII 2 5 1 To replace the tiller assembly P11 2 5 2 To remove the lower GO VOE ueque desk een nes P11 2 5 3 To replace the throttle lever or variable resistance cccccccccseseeceeesseeeceeseteeeseeseees P11 2 5 4 To replace the horn button or buzzer aaa P12 2 5 5 To replace the power indicator us P12 2 5 6 To replace the knob or potentiometer essssssssseeeeeeeeenee nennen enn P12 2 5 7 To replace the key and key switch P12 2 5 8 To replace the lower cover eee nennen enne nennen P13 The numbers shown in this service manual is just for reference The part numbers should be in accordance with current exploded drawing 1 Introduction The purpose of this manual is to provide dealers and or distributors with the product information and instructions that are required for servicing the S237 scooter 2 Service Guide The S237 scooter consists of five main parts B Seat Assembly B Battery Pack Assembly B Rear Section Assembly B Front Section Assembly B Tiller Assembly 2 1 How to replace or repair the Seat Assembly The seat assembly includes the seat body and the seat base plate assembly 2 1 1 To replace the seat body See Illus 01 When to replace the seat body lt gt The seat body is worn out pierced scratched or out of shape How to replace the seat body lt Pl
6. and screws 5 73 6 Remove mounting plate 5 67 and then replace variable resistance 5 66 To replace the horn button or buzzer See Illus 11 When to replace the horn button 5 58 and buzzer 5 59 lt gt The horn button or buzzer is not working properly How to replace the horn button and buzzer lt Please proceeding following steps 1 Loosen the nut on horn button 5 58 2 Remove replace the horn button 3 Loosen screws 5 60 and then remove replace the buzzer 5 59 To replace the power meter See Illus 11 When to replace the power meter lt gt The power indicator is not working properly How to replace the power meter 2 5 6 2 5 7 2 5 8 lt gt Please proceeding following steps 1 Unplug the cable of the power meter 5 55 2 Loosen screws 5 57 and then remove the clamp 5 56 3 Remove replace the power meter 5 55 To replace the knob or potentiometer See Illus 11 When to replace the knob or potentiometer lt The knob or potentiometer is not working properly How to replace the knob or potentiometer lt gt Please proceeding following steps 1 Loosen nut on knob 5 54 2 Remove replace the knob or potentiometer 5 62 To replace the key or key switch see Illus 11 When to replace the key or key switch lt gt The key or key switch is not working properly 9 How to replace the key or key switch lt gt Please proceeding following steps
7. and wrench to loosen the screw 1 12 and then take the spring 1 11 out 2 Loosen the screws 1 10 and remove the cover 1 09 3 Replace the frame clasper 1 08 Illus 08 2 4 5 To replace the front frame See Illus 10 When to replace the front frame lt gt The front frame is deformed or out of shape lt gt The scooter can not avoid bumping because of the deformed front frame How to replace the front frame lt gt Please proceeding following steps 1 Remove the front shroud See 2 4 1 2 Remove the controller See 2 4 2 3 Remove the frame clasper See 2 4 3 4 Remove the front wheel assembly See 2 4 4 5 Remove the tiller assembly See 2 5 1 6 Romove the seat post assembly See 2 1 1 7 Loosen screw 1 06 and remove tiller steering lock 1 04 8 Remove the headset bearing 1 02 9 Loosen screws 1 37 and remove the battery connector kit 1 3 10 Loosen screws 1 26 and then remove front connector kit 1 2 11 Replace the front frame 1 01 Illus 09 Illus 10 2 5 How to replace or repair the Tiller Assembly The tiller assembly is composed of tiller upper shroud lower shroud horn indicator light throttle lever power indicator and so on 2 5 1 To replace the tiller assembly See Illus 11 When to replace the tiller assemb
8. ease proceeding following steps Push down the seat free bar 4 08 to release the seat assembly 4 1 from the frame and pull it out 2 Use hex tools to loosen four screws 4 03 on seat base plate 4 02 and remove the seat body 4 01 2 1 2 To replace the armrest assembly See Illus 02 When to replace the armrest assembly lt The armrest is worn out pierced scratched or out of shape 9 How to replace the armrest assembly lt Please proceeding following steps Use hex tools to loosen the screws 4 05 and then take the armrest assembly 4 F out 2 Use screwdriver to loosen the screw 4 73 under armrest to disassemble armrest 4 72 from armrest support plate ta KI id Illus 01 ZA kA 4 FRN NS cs C 5 A j zs N 406 Stt B aus O 4 3 4 4 45 Illus 02 2 1 3 To replace the seat base plate assembly See Illus 01 amp 02 When to replace the seat base plate assembly lt gt The seat base plate is deformed or out of shape How to replace the seat base plate assembly lt gt Please proceeding following steps Please See 2 1 1 amp 2 1 2 2 20 How to replace or repair the Battery Pack Assembly The battery pack assembly is composed of the lower cover upper cover handle charger socket set circuit breaker two batteries multi electric harnesses and so on 2 2 1
9. embly lt gt There is noise on transaxle assembly lt gt The transaxle assembly is not working properly How to replace the transaxle assembly lt gt Please proceeding following steps 1 Loosen bolts 3 81 and remove mounting clamp 3 80 2 Loosen nuts 3 15 and release the motor wire attach to the connector kit 3 1 3 Loosen bolts that link motor 4 52 and transaxle 4 51 up 4 Loosen screws 4 54 and remove the release lever 4 53 5 Remove replace the motor or transaxle Illus 04 154 7 59 Illus 05 2 3 5 To replace the rear frame When to replace the rear frame lt gt If the rear frame is deformed or out of shape lt The scooter can not avoid bumping because of the deformed rear frame How to replace the rear frame lt gt Please proceeding following steps Remove the rear shroud See 2 3 1 Remove the anti tip wheel See 2 3 2 Remove the driven wheel See 2 3 3 Remove the transaxle assembly See 2 3 4 Loosen screws 3 16 and remove the connector kit 3 1 Replace the rear frame 3 01 S D BR D Illus 06 Illus 07 2 4 How to replace or repair the Front Section Assembly The front section assembly is composed of the front frame the controller the shroud the front wheel assembly the tiller assembly the frame clasper and so on
10. ly The tiller assembly is deformed or out of shape lt Any part of control panel is not working properly How to replace the tiller assembly lt gt Please proceeding following steps 1 Cut off all ties that bind the tiller main cable 5 80 on the front frame 2 Unplug the main cable 5 80 3 Use hex tools and wrench to loosen screws 5 12 and nuts 5 14 and then remove replace the tiller assembly 5 0 2 5 2 2 5 3 2 5 4 2 5 5 To replace the lower cover See Illus 11 When to replace the lower cover 5 79 lt gt The lower cover is broken How to replace the lower cover lt gt Please proceeding following steps 1 Use screwdriver to loosen 6 screws 5 81 and then separate the upper shroud and lower cover assembly 2 Unplug the connector which connect main cable 5 80 of tiller and control cable 5 64 and then remove replace the lower cover To replace the throttle lever or variable resistance See Illus 11 When to replace the throttle lever 5 75 or variable resistance 5 66 lt gt The throttle lever or variable resistance is not working properly 9 How to replace the throttle lever and variable resistance lt gt Please proceeding following steps Use hex tools to loosen the set screw 5 76 2 Remove replace the throttle lever 5 75 3 Loosen set screws 5 71 4 Remove throttle lever spring set 5 70 and torsion spring 5 69 5 Loosen the nut 5 68
11. ly the rear wheel assembly the fender the anti tip wheel and so on Press the black clasper 1 09 to separate the front and rear section See Illus 10 2 3 1 To replace the rear shroud See Illus 04 When to replace the rear shroud lt gt The rear shroud is out of shape lt The scooter can not avoid bumping because of the broken fender How to replace the rear shroud lt gt Please proceeding following steps Remove the plastic plug 7 67 2 Use screwdriver to loosen screws 7 64 3 Remove replace the rear shroud 7 5 2 3 2 2 3 3 2 3 4 To replace the anti tip wheel See Illus 05 When to replace the anti tip wheel lt gt The anti tip wheel is worn out lt gt The scooter can not avoid bumping because of the anti tip wheel 9 How to replace the anti tipper assembly lt gt Please proceeding following steps Use hex tools and wrench to loosen the screw 4 31 and nut 4 33 2 Remove replace the anti tip wheel 4 30 To replace the driven wheel assembly See Illus 06 When to replace the driven wheel assembly lt gt The driven wheel assembly is deformaed worn out or pierced How to replace the driven wheel assembly lt gt Please proceeding following steps Remove the hub cap 4 72 2 Loosen the nut 4 74 and washer 4 73 3 Remove replace the driven wheel 4 71 To replace the transaxle assembly See Illus 07 V When to replace the transaxle ass
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